IMechE 1st & 2nd Year Design Challenge - General Specification 2022-2

DESIGN
CHALLENGE
1 & 2 YEAR
st nd
GENERAL
SPECIFICATION
2022
IMechE DESIGN CHALLENGE
GUIDANCE FOR ALL PROJECTS
IMechE 1st & 2nd Year Design Challenge - General Specification 2022 - V1.0 .docx 1
IMechE 1st & 2nd Year Design Challenge - General Specification
General Specification
for the 2022
1st and 2nd Year Undergraduate
Design Challenge
Note: this specification must be read in conjunction with the respective document
“IMechE 1st (or 2nd) Year Design Challenge - Project
Specification”
Contents
1. Introduction and Purpose of the Design Challenge ............................................5

2. Prizes and Certificates ...................................................................................7
3. Sponsor Awards ...........................................................................................7
4. Rules for The Challenge .................................................................................7
5. Project Specification for The Challenge .......................................................... 10
6. Rules for the Design Competition .................................................................. 10
7. Scoring for the Design Competition. .............................................................. 12
8. Rules for the Poster Competition .................................................................. 13
9. Scoring for the Poster Competition ............................................................... 14
10. Rules for the Presentation Competition .......................................................... 15
11. Scoring for the Presentation Competition ....................................................... 16
12. Rules for the Peer Review Competition .......................................................... 17
13. Rules for the Design Excellence Competition .................................................. 18
14. Scoring for the Design Excellence Competition ............................................... 18
15. Enforcement of the Rules ............................................................................ 19
1. Introduction and Purpose of the Design Challenge

The purpose of the Design Challenge Competition is to simulate the requirements of a
professional engineer so that students are exposed to the real world of engineering where
they have to think for themselves and apply a systematic approach to solve an
engineering requirement.
Working in teams, students have to design, build and test a self-contained device from a
precise Project Specification.
The annual event takes place in three stages. Universities run internal qualifiers to select
up to two teams to progress to their respective Regional Finals. The winning university
from each region progresses to the National Final.
1.1 The competition is open to teams of two to five engineering degree students at the
appropriate level.
1.2 There are five competition elements to the Design Challenge at the Regional
Competition and National Final:
The Challenge
Design, build and test a device to compete with other teams.
CAD Design Competition

Create a virtual prototype of your device along with a Bill of Materials.
Poster Competition
Produce an A3 (portrait) poster to publicise the teams’ work. The poster is a

demonstration of the team’s ability to sell their design solution pictorially.
Presentation Competition
Give a short presentation explaining the design and development of their device, to
demonstrate their verbal & presentational skills, and to answer questions from the judges.
Peer Review (Regional Competition Only)
Submit a peer review where all students have the chance to vote for the best engineered
solution to the requirement.
Design Excellence (National Competition Only)

Present their designs to the judges to determine the best Engineering design using sound
principles with an acceptable appearance.
The above covers the general requirements of a professional engineer.
1.3 The format of the Regional Competition and National Final is as follows:
Regional Competition National Final

The Challenge The Challenge
Design Design
Poster Poster
Presentation Presentation
Peer Review Design Excellence
1.4 Points will be awarded for all sections of the competition.
1.5 All the points scored for each section of the competition will be totalled to determine
an outright champion.
The Challenge 35
Design 35
Poster 10
Presentation 10
Peer Review/Design Excellence 10
Total 100
1.6 Teams must compete in all sections of the competition to be crowned champions.
1.7 Prizes will also be awarded to the winners of each of the competition elements.
1.8 In the event of a tie of overall points, the team with the highest points in The
Challenge will be the champions.
The regional competitions are normally held in March or April, but this is not prescriptive
because it can be at any time to suit the universities in the region during the academic
year.
The National Final of the Design Challenge Competition is held in October of each year at
IMechE HQ.
2. Prizes and Certificates

In the Regional Competitions, each winning University will receive their Regional Design
Challenge Trophy to keep until the next Regional Competition, and a certificate. All members
of the winning team will receive a certificate.
In the National Final, the winning University will receive the prestigious Design Challenge
Trophy to keep until the next National competition, and a certificate. All members of the
winning team will receive a replica trophy to keep, together with a certificate.
Certificates will be available for the following, in both regional and national finals:
The runner up team

The third placed team
The winning team of the Design Competition
The winning team of the Presentation Competition
The winning team of the Poster Competition
The winning team of the Peer Review (Regional Competition)
The winning team of the Design Excellence Competition (National Final)
All members of the other participating teams will receive certificates
Certificates will only be awarded to participating team members and not to team
supervisors or university staff members.
3. Sponsor Awards
In addition to the IMechE prizes, the Sponsor Awards will be given by the competition
sponsors. These awards can be for specific aspects of the challenge, for teams and
individuals. They may also include opportunities for industrial visits or placements with the
sponsor. Please check for full details on the IMechE Design Challenge website for up-to-
date information.
Please note that the Sponsor Awards are not a formal, or obligatory, part of the
competition. The requirements for these awards have no bearing on the competition itself.
4. Rules for The Challenge

GENERAL
4.1 Devices should be manufactured using available facilities and materials, using
processes that students can do themselves with minimal guidance.
4.2 Off-the-shelf components may also be purchased, such as motors, batteries, gears,
bearings, fasteners and so on.
4.3 All components, whether manufactured or bought, must comply with the Design
Challenge regulations.
4.4 All devices must be ‘signed off’ by the academic staff member of the individual
university, to say that their team’s device meets all of the scrutineering rules.
4.5 On the day of the competition, and after successfully completing the scrutineering
process, teams will be given a sticker to be attached to the device as proof of
scrutineering.
4.6 Any team which tries to enter a heat without this sticker will not be allowed to
compete.
COST
4.7 The Total Cost of the device (including VAT at 20%) is to be as follows:
under £30 for the 1st year competition.

under £100 for the 2nd year competition.
4.8 The Total Cost, shown above, must include all parts and materials priced at, or
over, £0.20 used to make the device. Parts with a value of less than £0.20 do not
need to be included in the total cost.
4.9 A full parts list with all itemised costs, including those under £0.20, must be
produced according to the Design Competition rules (see Bill of Materials). This is
known as the BOM cost and is not the same as the Total Cost in 4.8.
4.10 All purchased materials and parts must be listed with the as-new normal retail
purchase price from established suppliers (including VAT, but excluding carriage).
4.11 Invoices, receipts, or proof-of-purchase must be available on the day of the

competition for all materials and bought components, for inspection by the judges
during the static competition and scrutineering.
4.12 Components or materials ‘in-kind’, or provided free by the university, or from any
other source, must be included in the parts list, and costed as appropriate at its as-
new price.
4.13 A component or material is considered to be ‘in-kind’ if it is not commercially

available for purchase by other teams or cannot be supplied at the same price.
4.14 In addition, the total cost must also include any replacement, or substitute parts,
used during the heats and final of The Challenge. This must include spare sets of
batteries, for example, changed during the heats, and they must be counted
towards the total cost of the device. This rule is to prevent teams using expensive
batteries and replacing them as new for each heat, without including them in the
cost. Put simply, any parts used on the device on the day of competition must be
included in the total cost.
4.15 Teams may be expected to justify the purchase price of any item of the device.
4.16 The cost of manufactured parts must be calculated based on the raw materials
used.
4.17 Standard sheet/bar materials should be charged as a proportion used per device,
within reason. For example, if the purchase of a 6m length of steel bar cost £18
and 200mm were used, the cost recorded would be £0.60 (£18 x 0.2 / 6.0).
Purchase of 600m of bar would be deemed unreasonable.
4.18 The cost of generic tools (drills, saws, files, etc.) need not be included. Likewise, the
cost of a battery charger, or air compressor, etc., can be excluded, as they are
considered general-use workshop items.
ADDITIVE MANUFACTURING
4.19 Rapid prototyping or additive manufacture is permitted. Teams should use this
method for making individual parts and not for producing the whole assembly.
4.20 Parts produced this way will be costed the same as other raw materials. For
instance, a 2.3kg reel of filament costing £57.00 will be costed at 2.48p per gram.
SAFETY
4.21 Teams are encouraged to think very carefully about safety and must provide a
signed risk assessment to accompany their device at the competition.
4.22 All devices and their risk assessment must be ‘signed off’ by the academic staff
members of the individual universities to say that their students’ devices are
deemed safe to operate in a lecture theatre or sports hall environment at the
competition.
4.23 Teams must supply their own safety glasses as appropriate. Teams that fail to
provide suitable safety equipment will have their top heat score erased.
4.24 Lithium batteries are not permitted due to the risk of fire and explosion, but other
types of safe, rechargeable batteries may be used.
4.25 Pressurised air/gas systems are allowed but they must be declared safe and
reasonable by the participating University and not subject to the “Pressure
Equipment Directive” (directive 97/23/EC) namely volume <1 L, pressure
volume<50 bar L.
4.26 No explosive charges or combustion can be used.
4.27 Consideration must be given to guarding if there is risk of entanglement or

entrapment.
5. Project Specification for The Challenge

The adopted project for The Challenge will change every year to prevent ongoing
development and convergence in performance. In each case this General Specification will
apply for the competition and the rules of engagement.
Please see the respective document “IMechE 1st (or 2nd) Year Design Challenge - Project
Specification” available on the IMechE Design Challenge website. This includes all the
technical regulations and rules needed for building a device to complete The Challenge.
6. Rules for the Design Competition

In the real world, virtual prototyping and simulation can significantly reduce development
times and costs. Product development requires a judgement to be made between this and
the level of physical prototyping and testing that is required. A balance has to be found to
ensure that a high-quality, durable, reliable product is delivered to budget and on time.
The Design Competition is made up of three elements: a virtual prototype, a bill of

materials and a design review.
To demonstrate their ability to create a concept, teams are required to submit a virtual
prototype of their design. The ultimate aim is to produce a 100% realistic model of the
design, which is accurate in every detail, so that it represents exactly what will be built.
The Computer Aided Design (CAD) will be submitted to the judging panel ahead of the
competition date.
6.1 Teams are required to submit a fully-detailed virtual design of a device that will
complete the IMechE Design Challenge.
6.2 The virtual prototype must match the device that competes in the Main Competition
and will be judged for similarity on the day.
6.3 In terms of physical similarity, assemblies must include the finer detail, such as
fasteners.
6.4 Wiring is one of the most difficult items to model in 3D. Teams are encouraged to
attempt to model wires to gain experience, but this will not form part of the
scoring.
6.5 The virtual prototype is to be submitted in STEP AP203 format via the IMechE
Design Challenge website. Details will be circulated to teams at the time.
6.6 Teams are strongly advised to check the integrity of their STEP file before
submitting it, to check for any translation errors, and to ensure that it includes the
complete assembly of the device with no parts missing.
6.7 Submitted models must be an assembly of individual solid bodies, and not one
single entity.
6.8 Individual parts within the assembly must be solids with mass and volume, and not
surface models, which are just a shell.
Teams must also submit a Bill of Materials (BOM) to accompany their design. This is a
detailed parts list which also includes information such as materials, cost and suppliers.
Please see the supplementary document “IMechE Design Challenge – BOM Template”.
Teams must use the IMechE Excel spreadsheet template which is provided.
6.9 Teams must submit a Bill of Materials (BOM) to accompany their virtual prototype.
The BOM must include the following information for each item, in the BOM template
that will be provided:
Part Name
Part Number
Quantity
Material
Density – in kg/m3
Mass – in kg
Cost – in £0.00
Supplier
Hyperlink to supplier’s website
6.10 Every individual item must be included in the cost entry in the BOM. This includes
items costing less than 20p.
6.11 The BOM template will have two totals, one for items costing more than 20p (the
Total Cost, rule 5.7), and one for items less than 20p (the BOM Cost).
6.12 Material and density properties are included so that judges can verify the accuracy
of the model by applying material properties to individual components to check the
calculated masses provided in the BOM.
At the Regional and National Finals, every team will take part in a design review
conducted by the IMechE judging panel. During the review the judges will discuss aspects
of the design that they may have noted during preliminary scoring of the virtual designs.
6.13 CAD models will be projected onto the screen during the review by the judges.
6.14 The length of the design review will last for 5 minutes per team, but this may vary
depending on the number of teams taking part.
7. Scoring for the Design Competition.

The virtual prototype and bill of materials will be assessed in accordance with the scheme
below:
Judging Criteria Weight (%)
Overall quality of the virtual prototype model 20

Prototype
Virtual
Inclusion of the finer details such as fasteners and standard parts 10
Compliance with Design Challenge rules 5
Overall accuracy of the BOM – including all items in the assembly 10

Materials
Bill of
Cost analysis for the entire device, including items less than 20p 10
Accuracy of costs for manufactured parts and bought components,

5
including spares
Mass of the actual device compared to the calculated BOM mass 5

Competition
Review at
Cost analysis includes all prices inc. VAT 5
Accuracy of the virtual model compared to the real device on display,

including fasteners and standard parts 10
Design review 20
Total 100
Score = Total / 10
10
Rounded up to a whole number
8. Rules for the Poster Competition

8.1 The poster should be A3 size in portrait format. It should clearly display the logos of
the team’s university and of the IMechE.
8.2 The poster should concisely describe the device, how it operates and the
engineering principles it is based on. It should include, but is not limited to:
a. sketch, 3D visualisation or 2D technical drawings representing the device,

b. text to explain important features shown in the drawings,
c. details of how and why the device works, using diagrams if necessary, and
d. brief details of the team members.
8.3 Detailed costing of the device is not required on the poster, but a summary of the
Total Cost should be included.
8.4 Each team should display their poster on the board provided and display their
device on the table with their poster.
8.5 Posters must also be submitted electronically no later than 2 weeks ahead of the
date of the Regional Competition or National Final. Details will be circulated to
teams at the time.
8.6 The submitted poster is the version that will be judged.
9. Scoring for the Poster Competition

The poster will be assessed in accordance with the scheme below:
Compliance with rules – size (A3) and orientation (portrait) 10

Impact
Visual
Obvious information on the university represented (logos) and the team

10
members’ names
Good use of colour, layout, text and space to convey meaning 10
Clear but brief textual description of the competing device 10
Clear diagram(s) – sketch, rendering or CAD model – of the device 15

Technical
Content
Evidence of the engineering science underpinning the device 15
Facts and figures for the performance characteristics of the device 15
Summary costing of major components of the device 15
Total 100
Score = Total / 10
10
10. Rules for the Presentation Competition

10.1 The maximum length of the presentation is five minutes.
10.2 The presentation should be delivered by all the team members.
10.3 The presentation should include, but is not limited to;
a. the principal features of the final design,

b. the engineering science that underpins the device,
c. the steps the team followed to arrive at the design, and
d. the total cost of the final design and if/how costs influenced the final design
10.4 The presentation must be recorded and submitted electronically no later than 2
weeks ahead of the date of the Regional Competition or National Final. Details will
be circulated to teams at the time.
10.5 The submitted presentation is the version that will be judged.
10.6 At the Regional and National Finals the top three teams will be announced at the
event and their presentations will be shown live.
10.7 The top three teams will answer questions on their design for up to three minutes.
11. Scoring for the Presentation Competition

The presentation will be assessed in accordance with the scheme below:

Presentation
Audience Engagement 15
Style
Quality of spoken presentation (well structured, fluent, clear etc.) 15

Quality of visual aids (clear and easily readable, do not duplicate
15
spoken presentation etc.)
Principal features of the final design 15
Technical
Content
Steps followed to reach the final design, including costing of the

15
device
Engineering science that underpins the final design 15
Q&A Answer to judges’ questions (top three teams only) 10
Total 100
Score = Total / 10
10
12. Rules for the Peer Review Competition

12.1 The Peer Review Competition takes place in the Regional Final.
12.2 Each team should examine the device from all of the other teams without handling
them.
12.3 During the examination teams should be looking for the following;
a. design principles used,

b. the simplicity of the design,
c. the robustness of the design,
d. the manufacturing excellence, and
e. the general appearance.
12.4 Teams then vote for their top three using the voting slips provided by the IMechE
on the day.
12.5 Whilst the peer review is being carried out there must be at least one member of
each team present to answer questions etc.
13. Rules for the Design Excellence Competition

13.1 The Design Excellence Competition takes place in the National Final.
13.2 The device will be judged under the same criteria as the Peer Review.
13.3 Whilst the design excellence judging is being carried out there must be at least one
member of each team present to answer questions etc.
14. Scoring for the CAD Design Excellence Competition

The design excellence will be assessed in accordance with the scheme below:
CAD Model 20
Design principles applied 20
Robustness & Simplicity of design 20
Manufacturing excellence 20
Appearance 20
Total 100
Score = Total / 10
10
15. Enforcement of the Rules

15.1 On matters relating to test equipment and procedure, the authority will be the Chair
of the IMechE Design Challenge organising committee, or his/her delegated
representative(s).
15.2 The panel of judges for the competition consists of impartial IMechE and university
representatives.
15.3 The decisions of the panel of judges will be final.
15.4 In addition to the IMechE outlined above, universities are responsible for internally
ensuring that the spirit of the competition is adhered to during the design and make
stages.
15.5 Appeals: If a team wishes to lodge a complaint, to query a procedure or rule

infringement, they must do so through the Chair of the IMechE Design Challenge
organising committee, or his/her delegated representative(s). Any complaint will be
investigated immediately, by at least two judges, and a response will be issued
within a reasonable time. This decision will be final and not subject to further
appeal.
15.6 Appeals must be raised by a nominated team leader. The remaining team members,
team supervisors, or university staff members, can only contribute to an appeal if
requested to do so by the Chair of the IMechE Design Challenge organising
committee, or his/her delegated representative(s).
Note - Judges are allowed to vary the rules slightly, if it is deemed necessary, to maintain
the smooth running of the competition.

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DESIGN

1. Introduction and Purpose of the Design Challenge ............................................5

1. Introduction and Purpose of the Design Challenge

CAD Design Competition

Produce an A3 (portrait) poster to publicise the teams’ work. The poster is a

Peer Review (Regional Competition Only)

Design Excellence (National Competition Only)

The above covers the general requirements of a professional engineer.

Regional Competition National Final

1.4 Points will be awarded for all sections of the competition.

2. Prizes and Certificates

The runner up team

4. Rules for The Challenge

under £30 for the 1st year competition.

4.11 Invoices, receipts, or proof-of-purchase must be available on the day of the

4.13 A component or material is considered to be ‘in-kind’ if it is not commercially

4.26 No explosive charges or combustion can be used.

4.27 Consideration must be given to guarding if there is risk of entanglement or

5. Project Specification for The Challenge

6. Rules for the Design Competition

The Design Competition is made up of three elements: a virtual prototype, a bill of

7. Scoring for the Design Competition.

Judging Criteria Weight (%)

Overall quality of the virtual prototype model 20

Inclusion of the finer details such as fasteners and standard parts 10

Compliance with Design Challenge rules 5

Overall accuracy of the BOM – including all items in the assembly 10

Accuracy of costs for manufactured parts and bought components,

Mass of the actual device compared to the calculated BOM mass 5

Cost analysis includes all prices inc. VAT 5

Accuracy of the virtual model compared to the real device on display,

8. Rules for the Poster Competition

a. sketch, 3D visualisation or 2D technical drawings representing the device,

8.6 The submitted poster is the version that will be judged.

9. Scoring for the Poster Competition

Judging Criteria Weight (%)

Compliance with rules – size (A3) and orientation (portrait) 10

Obvious information on the university represented (logos) and the team

Good use of colour, layout, text and space to convey meaning 10

Clear but brief textual description of the competing device 10

Clear diagram(s) – sketch, rendering or CAD model – of the device 15

Evidence of the engineering science underpinning the device 15

Facts and figures for the performance characteristics of the device 15

Summary costing of major components of the device 15

10. Rules for the Presentation Competition

10.2 The presentation should be delivered by all the team members.

10.3 The presentation should include, but is not limited to;

a. the principal features of the final design,

10.5 The submitted presentation is the version that will be judged.

11. Scoring for the Presentation Competition

Judging Criteria Weight (%)

Quality of spoken presentation (well structured, fluent, clear etc.) 15

Steps followed to reach the final design, including costing of the

Q&A Answer to judges’ questions (top three teams only) 10

12. Rules for the Peer Review Competition

a. design principles used,

13. Rules for the Design Excellence Competition

14. Scoring for the CAD Design Excellence Competition

Judging Criteria Weight (%)

Design principles applied 20

Robustness & Simplicity of design 20

15. Enforcement of the Rules